Siding system or roof shingle system comprising cementitious material, and systems and methods for manufacturing the same

ABSTRACT

A board-type or log-shaped cementitious siding system, or a cementitious roof shingle system, having a reinforcement material contained therein, and an optional foam insert at least partially enveloped by a cementitious shell. Each system is molded from cementitious slurry, including gypsum cement and a latex/water mixture. A reinforcement material and an amount of the slurry are introduced into an open molding system or an alternative closed molding system, either molding system including a mold surface member having a face defining an exposed surface of the siding or roof shingle system. The slurry introduced to the mold surface member is to a desired depth and/or weight, or for a desired period of time. A foam insert is optionally introduced into the molding system. After sufficient curing, the siding or roof shingle system is separated from the mold surface member and is ready for immediate use and/or further processing. Alternatively, a system and method are provided for continually producing board-type cementitious siding systems and cementitious roof shingle systems that may be elongate and can be cut to an appropriate size, without the need to produce individual siding or roof shingle systems of limited size. The cementitious siding and roof shingle systems continually produced thereby are ready for immediate use and/or further processing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplications Nos. 61/100,095, 61/100,124, and 61/100,144, all filed Sep.25, 2008, the disclosures of which are each hereby incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to siding systems and roofshingle systems, and more specifically to such systems formed fromcementitious slurries, especially those containing gypsum, and processesfor their manufacture.

2. Description of the Related Art

Many homes in North America use brick, vinyl siding, aluminum siding, orwood as the material comprising the exterior walls thereof. Brickprovides excellent aesthetic, weather protection, and insulationproperties, and is virtually maintenance free. However, brick isconsiderably more expensive to install than the other three primarysiding materials due to the high labor costs.

Vinyl siding is made from PVC (polyvinyl chloride) and has begun to beused in construction more and more all the time. Vinyl siding can befashioned to resemble wood, with the average width of vinyl sidingranging from 6 inches to 10 inches. However, other various lengths andwidths are available. Scratches are rarely visible, because the PVC thatthe siding is composed of is solid all the way through. Vinyl siding issimilar in many properties to aluminum, such as weight and density.However, unlike aluminum, vinyl does not dent, and besides aestheticrepair, scratched vinyl siding does not rust and will not ruin theintegrity of the siding. Temperature will not affect vinyl siding, whichcan be installed in nearly any climate. Aluminum siding might take along time to re-install if damaged, which is untrue of vinyl siding.Vinyl's temperature at which it ignites is very high (736° F.), and ithas half the burn time of cedar and burns one third as hard.

Aluminum siding is also one of the most popular exterior home coverings.It is more common than seamless siding systems because steel tends torust when exposed for a long period of time, unlike aluminum Like vinylsiding, aluminum siding is relatively low-maintenance in its first fewyears. Aluminum siding comes in long panels, so it takes less time toinstall. It has baked on enamel that can be flat or shaped to resemblewood grain. Aluminum siding is waterproof, a good insulator, and themost fireproof type of siding. Unfortunately, aluminum siding issusceptible to dents and can be difficult to repair once it's beencompletely installed. For the first few years, aluminum siding requireslittle maintenance. However, it soon may show signs of cracking, rust,and peeling. After two or three years, the home owner should beginmonitoring the aluminum siding for dents and other marks. Eventually,damaged panels should be repainted or replaced, which is atime-consuming and potentially expensive process.

The most common type of siding for a house is wood (e.g., cypress,cedar, redwood, and/or the like) which provides an attractive appearanceand good insulation properties. However, as evidenced by the fact thatmore and more consumers are choosing vinyl, aluminum, and other sidingchoices, there are a number of drawbacks.

Wood in general is a haven for animals and insects. For example, manywoodpeckers and other birds are drawn to the wood on the outside ofhouses. It is thought that tannin, a resin that is found in cedar is anatural insect repellent. However, the same tannin can cause rain spotsthat will appear for the first three years that the cedar is on thehome. Redwood is much like cedar except that its color is slightlydifferent.

Plywood, which is a common type of siding, is usually composed ofwestern red fir, yellow pine, and Douglas fir. Either roughhewn orsmooth, plywood is usually attached to a home horizontally and isn't thebest way to protect from water damage. However, plywood is attractivefor its natural look, and many ways are being developed to strengthenits structural integrity. Clapboard is simply long boards of woodapplied horizontally and overlapping on a house. The result can lookuneven and irregular, but beveled or tapered boards can correct thisproblem. Hardboard or composition board is comprised of compressed woodfiber and adhesives that are weather resistant are applied to planks orsheets of wood to strengthen them and make them more waterproof.Hardboard can measure 16 feet in length, though many people have it cutto better resemble clapboard. Plywood siding is comprised of a veneer isa slice of wood of constant thickness, and it is applied to hardwood toform hardwood siding. More durable than indoor plywood, it is also muchmore waterproof. Rectangular plank siding is comprised of smooth planksthat meet each other evenly. When laid vertically, they form a flatsurface that is interrupted only by battens designed to keep moistureout. Wood plank siding is very much like rectangular plank siding inthat boards are laid vertically and protected from water damage.However, wood plank siding comes in many shapes and can be cut manydifferent ways to give texture and a pattern.

A rustic, pastoral look can be achieved by using shake siding, which ismade up of hand-split, irregular cedar sidings. They are rough andeither put on all at once or in layers to use weathering as an effectfor patterns. They are susceptible to cracking, warping and curling, sothey should be checked often and replaced when necessary. Unlike shakes,sidings are machine cut, smooth and uniform. They are increasinglyoverlapped as they are higher on the house, however many people createtheir own patterns and decide the degree to which there is an overlapLike shakes, sidings can fall victim to warping, cracking, and curling.

Any wood siding product, but especially less protected wood, like shakesand sidings, should be kept away from moisture and protected from theelements. Typically this involves the regular application of stains,sealants, and paints, and is generally an expensive and time-consumingprocess. Failure to properly maintain the wood siding product can leadto irreparable damage and potential rotting of the wood, necessitatingexpensive repairs.

A recent product in the siding market has been asbestos-freefiber-cement siding. Its market share is on the rise, but it still lagsbehind wood and vinyl siding. Fiber-cement siding generally is moreexpensive than aluminum or vinyl siding, but it costs less than brick ortraditional cedar siding. It is sold under a number of brand names,including HARDIPLANK, CEMPLANK, and WEATHERBOARDS. To make the siding,manufacturers mix cement, sand and cellulose fibers with water. Theplanks are offered in various widths in both horizontal and verticalstyles. They can be given a smooth look or finished with a heavier woodgrain appearance. James Hardie Building Products, which makes theHARDIPLANK line, has introduced a plank that simulates the look ofsidings to use as an accent on a home. A big selling point is thatfiber-cement siding offers a number of benefits over wood. For example,this siding resists damage from the elements and insects, and providesvery good structural strength and good impact resistance. From a safetystandpoint, the fiber-cement siding itself won't burn, but the finishingmaterials (e.g., paints) applied thereto might. Though makers of thefiber-cement siding tout its low-maintenance qualities, it does, asnoted, need to be painted periodically. Attaching fiber-cement siding toa home is similar to applying wood siding; however, this type of sidingis heavier, more difficult to cut, and generally more difficult toinstall than traditional siding materials.

Additionally, homes constructed of logs, whether they be conventionallyrough hewn logs, engineering log products, or laminated log products,have become increasingly popular, especially for use in rural areas,e.g., a vacation homes, hunting lodges, and/or the like. While log homesare very attractive, there are several drawbacks associated with them.Initially, they require a substantial amount of trees to be cut down toform the requisite number of logs. From an environmental andconservation perspective, this is not desirable. Also, the cost ofconstructing and maintaining a log home can be considerably moreexpensive than a conventional stick and frame house of similardimensions. Additionally, log homes are susceptible to structuralproblems as the logs begin to settle (e.g., due to improper drying),such as sagging door and window frames, checked and split logs, waterand insect infiltration, and/or the like.

Although engineered and laminated log products (which attempt to providean exterior and/or interior wall face that mimics a log cabin appearancewith the use of a reduced amount of total wood to produce the logproducts) have addressed some of these drawbacks to a certain extent,buildings having walls constructed of logs are nonetheless still notentirely satisfactory from an environmental, conservation, cost and/ormaintenance viewpoint.

With regard to roof shingle systems, approximately 80% of the homes inNorth America use asphalt shingles or tiles as the roofing material ofchoice. The primary attributes of asphalt tiles are reasonable price,low maintenance, and versatility. There are two different types ofasphalt shingle base material construction: composition and fiberglass.Composition shingles use a base material termed organic felt, which is ablend of paper and wood fibers. Fiberglass, on the other hand, uses abase that is comprised of a fiberglass mat. In both cases, once the basematerial is produced it is soaked in an asphalt compound. In numberssold, fiberglass leads the market. They are less expensive, weigh lessbecause they are thinner, have a longer wear life and have a better firerating than the composition base shingles.

Where just a few years ago asphalt shingles were only available insimple tab configurations in blacks, grays and browns, the manufacturershave expanded their product lines to include a vast array of colors,profiles and with the use of laminate coatings have created asassortment of eye pleasing textures. Special chemicals are also beingblended into the shingles to make them mold and algae resistant.Although these additional features do increase the price per square,asphalt shingles are still the most economical roofing materialavailable.

However, the serviceable life of asphalt shingles is the lowest of allthe roofing materials. Although they are available in numerous gradesdesignated by the expected life, from 15 to 50 years, they often needrepair or replacement long before their supposed life has expired. Thehotter the climate, the shorter the life of asphalt shingles. Many ofthe asphalt shingle problems that are encountered by homeowners are adirect result of three primary factors: poor initial installation, poorattic ventilation, and damage due to severe weather conditions.

One alternative to asphalt roof shingles is the natural slate roofshingle. A slate roof is one of the most durable roofing materialsavailable. When properly installed and maintained, a slate roof canpotentially last for more than a hundred years. The specific life of aslate roof is dependent upon several variables, such as type and originof the slate, roof style, and climate.

Another consideration is the weight of slate tile. Many roofs are notstructurally designed to handle the load represented by a slate tileinstallation. Before committing to the installation of a slate roof, ahomeowner must ensure that the house's rafters and/or trusses have beendesigned and installed to handle the additional weight. Retrofitting ofan existing home's roof support structure to accommodate a slate tileroof can be a very expensive and time-consuming undertaking.

Considered to be the most stylish and sophisticated roofing materials,slate comes in a wide range of colors, textures and quality levels.Because a slate roof installation requires skilled, professional andexperienced roofers, slate is a much more expensive roof covering thanconventional asphalt roof shingles. In addition, because of the productsweight, special handling equipment is required and freight charges willadd to the installation costs. For example, a homeowner can expect topay around $1,000 per roofing square (i.e., 100 square feet), as opposedto conventional asphalt shingles which cost around $50-$150 per roofingsquare to install.

Therefore, it would be advantageous to provide durable and economicalsiding systems and roof shingle systems, and methods for forming thesame, which overcome at least one of the aforementioned problems.

SUMMARY OF THE INVENTION

The present invention provides siding systems and roof shingle systems,and methods for forming the same, comprised of a cement or cementitiousexterior shell at least partially enveloping an optional foam core,wherein the cementitious materials especially contain gypsum (e.g.,calcined gypsum). According to one embodiment of the present invention,a siding system or a roof shingle system is formed in a substantiallyopen mold from cementitious slurry comprising gypsum cement (e.g.,calcined gypsum) and a latex/water mixture. The slurry can also containother materials, such as but not limited to reinforcement materials(e.g., fibers, scrims, netting, meshes, and/or the like), as well asother materials that are known in the art (e.g., activators, setpreventers, plasticizers, fillers, and/or the like), which can be addedbefore and/or after the combination of the gypsum and latex/watermixture.

The present invention provides a siding system or roof shingle systemconfigured to simulate, and intended to be a substitute for, traditionalsiding or roof shingles, respectively. Such a system includes at leastone of a plurality of members adapted for being mounted to a dwelling,the member including a cementitious material defining a first surfaceexposed relative to a dwelling to which the plurality of members isadapted for being mounted. The first surface is configured to simulatethe appearance of at least one singular traditional siding element orroof shingle element. The member further includes a reinforcementmaterial encapsulated by the cementitious material and disposedproximately beneath the first surface, with the reinforcement materialextending substantially over the area of the first surface. The memberincludes a second surface opposed to the first surface and defining areverse surface that faces the dwelling surface to which the pluralityof members is adapted for being mounted. The member first surface isconfigured to simulate the appearance of at least one singulartraditional siding or roof shingle element. Examples of such singularelements include a wooden board, a wooden shake, a wooden shingle, alog, a slate roof tile, and an asphalt roof shingle. Further, the memberoptionally includes a foam core at least partially enveloped by thecementitious shell and disposed on the side of reinforcement materialopposite the first surface.

With respect to one embodiment of a production process for manufacturinga siding system or a roof shingle system according to the presentinvention, an appropriate amount of the cementitious slurry is addedonto a bottom mold surface portion to a desired depth. The slurry cancontain colorants dispersed therethrough, or alternatively, the bottommold surface can be coated with a colorant. A reinforcement material(e.g., fibers, scrims, netting, meshes, and/or the like) can be added tothe mold either before or after introduction of the cementitious slurry.An optional foam core can then be placed atop the cementitious slurry ina desired orientation. An additional amount of the cementitious slurrycan then be added on top of the foam core so as to at least partiallyencapsulate the foam insert, especially in the region where any mountingmembers have been inserted. Alternatively, the optional foam core couldbe left exposed. An optional top mold surface can be employed to ensurethat the foam core does not float out of the cementitious slurry. Duringone or more of the aforementioned stages, the mold can be vibrated andforce/pressure applied. After an appropriate curing or drying time, theproduct (e.g., a siding system) is removed from the mold and is readyfor immediate use and/or further processing.

Alternatively, relative to certain siding system and roof shingle systemembodiments, a continuous method is also provided for producingrelatively long lengths thereof that can be cut to an appropriate size,without the need to produce individual siding systems or roof shinglesystems of limited size.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating preferred embodiments of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is an elevational view of a dwelling having a board-typecementitious siding system, in accordance with a first embodiment of thepresent invention;

FIG. 2 is a partial elevational view of a dwelling having an alternativeboard-type cementitious siding system, in accordance with a secondembodiment of the present invention;

FIG. 3 is an elevational view of a dwelling having a log-shapedcementitious siding system, in accordance with a third embodiment of thepresent invention;

FIG. 4 is a perspective view of a board-type cementitious siding memberor siding system, in accordance with a fourth embodiment of the presentinvention;

FIG. 5 is a perspective view of an alternative board-type cementitioussiding member or siding system, in accordance with a fifth embodiment ofthe present invention;

FIG. 6 is a perspective view of a log-shaped cementitious siding memberor siding system, in accordance with a sixth embodiment of the presentinvention;

FIG. 7 is a partial perspective view of a dwelling having a cementitiousroof shingle system, in accordance with a seventh embodiment of thepresent invention;

FIG. 8 is a perspective view of a cementitious roof shingle member orroof shingle system, in accordance with an eighth embodiment of thepresent invention;

FIG. 9 is a perspective view of a mold surface member of a moldingsystem for forming a board-type cementitious siding member or sidingsystem, in accordance with a ninth embodiment of the present invention;

FIG. 10 is a perspective view of a mold surface member of a moldingsystem for forming an alternative board-type cementitious siding memberor siding system, in accordance with a tenth embodiment of the presentinvention;

FIG. 11 is a perspective view of a mold surface member of a moldingsystem for forming a log-shaped cementitious siding member or sidingsystem, in accordance with an eleventh embodiment of the presentinvention;

FIG. 12 is a perspective view of a mold surface member of a moldingsystem for forming a cementitious roof shingle member or roof shinglesystem, in accordance with a twelfth embodiment of the presentinvention;

FIG. 13 is an exploded view of a mold surface member and a lower orbottom mold retainer support of a molding system for forming aboard-type cementitious siding member or siding system, in accordancewith a thirteenth embodiment of the present invention;

FIG. 14 is an exploded view of a mold surface member and a lower orbottom mold retainer support of a molding system for forming alog-shaped cementitious siding member or siding system, in accordancewith a fourteenth embodiment of the present invention;

FIG. 15 is an exploded view of a mold surface member and a lower orbottom mold retainer support of a molding system for forming acementitious roof shingle member or roof shingle system, in accordancewith a fifteenth embodiment of the present invention;

FIG. 16 is a perspective view of a lower or bottom mold retainer supportand a conveyor system of a molding system for forming cementitioussiding or roof shingle members or systems, in accordance with asixteenth embodiment of the present invention;

FIG. 17 is an exploded view of a mold surface member being placed in alower or bottom mold retainer support on a conveyor system of a moldingsystem for forming a board-type cementitious siding member or sidingsystem, in accordance with a seventeenth embodiment of the presentinvention;

FIG. 18 is an exploded view of a mold surface member being placed in alower or bottom mold retainer support on a conveyor system of a moldingsystem for forming a log-shaped cementitious siding member or sidingsystem, in accordance with an eighteenth embodiment of the presentinvention;

FIG. 19 is an exploded view of a mold surface member being placed in alower or bottom mold retainer support on a conveyor system of a moldingsystem for forming a cementitious roof shingle member or roof shinglesystem, in accordance with a nineteenth embodiment of the presentinvention;

FIG. 20 is an exploded view of a reinforcement material being placedinto the mold surface member of FIG. 17, in accordance with a twentiethembodiment of the present invention;

FIG. 21 is an exploded view of a reinforcement material being placedinto the mold surface member of FIG. 18, in accordance with atwenty-first embodiment of the present invention;

FIG. 22 is an exploded view of a reinforcement material being placedinto the mold surface member of FIG. 19, in accordance with atwenty-second embodiment of the present invention;

FIG. 23 is a perspective view of cementitious slurry being added ontothe reinforcement material in the mold surface member of any of FIGS.20-22, in accordance with a twenty-third embodiment of the presentinvention;

FIG. 24 is an exploded view of an optional foam core material beingplaced into cementitious slurry previously added to the mold surfacemember of any of FIGS. 20-22, in accordance with a twenty-fourthembodiment of the present invention;

FIG. 25 is a perspective view of the optional foam core material of FIG.24 placed in the cementitious slurry and mold surface member prior to anoptional additional quantity of cementitious slurry being added to themold surface member, in accordance with a twenty-fifth embodiment of thepresent invention;

FIG. 26 is an exploded view of a mold surface member containing a formedcementitious siding or roof shingle member or system being removed froma lower or bottom mold retainer support, in accordance with atwenty-sixth embodiment of the present invention;

FIG. 27 is an exploded view of a finished board-type cementitious sidingmember or siding system being separated from its mold surface member, inaccordance with a twenty-seventh embodiment of the present invention;

FIG. 28 is an exploded view of a finished log-shaped cementitious sidingmember or siding system being separated from its mold surface member, inaccordance with a twenty-eighth embodiment of the present invention;

FIG. 29 is an exploded view of a finished cementitious roof shinglemember or roof shingle system being separated from its mold surfacemember, in accordance with a twenty-ninth embodiment of the presentinvention;

FIG. 30 is a schematic view of a first alternative system forcontinuously producing cementitious siding or roof shingle members orsystems of the present invention, in accordance with a thirtiethembodiment of the present invention;

FIG. 31 is a schematic view of a second alternative system forcontinuously producing cementitious siding or roof shingle members orsystems of the present invention that include a foam core, in accordancewith a thirty-first embodiment of the present invention;

FIG. 32 is an exploded view of an alternative molding system for forminga log-shaped cementitious siding member or siding system, in accordancewith a thirty-second embodiment of the present invention;

FIG. 33 is a partial sectional view of the molding system of FIG. 32, inaccordance with a thirty-third embodiment of the present invention; and

FIG. 34 is a partial sectional view of the molding system of FIG. 32wherein an optional foam core or insert is shown for inclusion in theformed log-shaped cementitious siding member or siding system, inaccordance with a thirty-fourth embodiment of the present invention.

Corresponding reference characters indicate the same or correspondingparts throughout the several views. Moreover, it is to be noted that theFigures are not necessarily drawn to scale and or drawn to the samescale. In particular, the scale of some of the elements of the Figuresis greatly exaggerated to emphasize characteristics of the elements.Elements shown in more than one Figure that may be similarly configuredhave been indicated using the same reference numerals.

DETAILED DESCRIPTION OF THE INVENTION

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention.

Referring to the Figures generally, and specifically to FIGS. 1-8,cementitious siding systems and roof shingle systems are generallydisclosed at 10. By “system,” as that term is used herein, it is meantat least one siding member which each may, for example, simulate theappearance of one or more wall-siding boards, shakes, shingles or logs,or at least one roof shingle member which each may, for example,simulate the appearance of one or more asphalt, natural slate or cedarroof shingles or roof tiles, each member of either type is generallydesignated 12. Each cementitious siding member or roof shingle member 12is a separate, individual unit a siding or roof shingle system 10.

Each cementitious siding member 12 may itself represent a cementitioussiding system 10 as explained above, and a cementitious siding system 10may include one or a plurality of individual siding members 12. Further,each cementitious siding member 12 may simulate a singular traditionalsiding element. For example, a siding member 12 may simulate a singlewooden shake, or a single log. Alternatively, each siding member 12 maysimulate two or more such singular siding elements in a single,integrally-formed unit. For example, a siding member 12 may simulate aplurality of adjacently positioned wooden shakes, or a plurality ofadjacently positioned logs.

Similarly, each cementitious roof shingle member 12 may itself representa cementitious roof shingle system 10 as explained above, and acementitious roof shingle system 10 may include one or a plurality ofindividual roof shingle members 12. Further, each cementitious roofshingle member 12 may simulate a singular traditional roof shingleelement. For example, a roof shingle member 12 may simulate a singlenatural slate roof tile, or a single asphalt roof shingle tab.Alternatively, each roof shingle member 12 may simulate two or more suchsingular roof shingle elements in a single, integrally-formed unit. Forexample, a roof shingle member 12 may simulate a plurality of adjacentlypositioned natural slate tiles, or a plurality of adjacently positionedasphalt roof shingle tabs (thus configured like a conventional multi-tabasphalt roof shingle). In the discussion that follows, and in thedrawings, the exemplary cementitious siding and roof shingle systems 10and cementitious siding and roof shingle members 12, and theirassociated mold surface members 204, are provided with a letter suffixA, B, C, D generally associated with the system or member embodiment ormolding system being discussed.

Although the present invention will be described with primary referenceto siding systems and roof shingle systems, it should be appreciatedthat the present invention can be practiced with any type ofarchitectural and exterior/interior decorative element, especially thosehaving a foam core or insert, regardless of whether the foam core orinsert is partially or fully enveloped by a cementitious slurry and/orthe like.

The siding system or roof shingle system 10 can be mounted, eitherpermanently or temporarily to a dwelling, such as a residential orcommercial building. In the examples illustrated in FIGS. 1-3 and 7, thecementitious siding or roof shingle systems are mounted to a house 11.The siding systems 10 are rigidly secured to the exteriors walls ofhouse 11 by appropriate securing devices, such as but not limited tonails, bolts, screws, and/or the like. By way of a non-limiting example,the siding systems 10 can be formed with apertures provided therein forreceiving the securing devices.

With specific reference to FIGS. 1 and 4, a board-type cementitioussiding system 10A can simulate wooden board siding, such as lap orclapboard siding. As used herein, “board-type” refers to the generalconfiguration of the cementitious siding member 12, rather than to thetype of traditional siding element(s) simulated thereby. Generally,board-type siding members 12 are flat or planar, and may also beelongate. In the illustrated embodiment, cementitious siding system 10Ais a single cementitious siding member 12A, or a plurality thereof. Eachmember 12A simulates a singular wooden board, a cross section of whichtaken normal to its longitudinal direction is substantially rectangular(as shown in FIG. 4) but may instead be slightly tapering from itsbottom edge to its top edge. Surface texture 14A is molded into theexposed exterior surfaces of member 12A, providing a three-dimensional,simulated wood grain.

With specific reference to FIGS. 2 and 5, an alternative board-typecementitious siding system 10B of the present invention can include,without limitation, a “cedar shake” or “cedar shingle” like appearance.In this view, the alternative board-type cementitious siding system 10Bis a single cementitious siding member 12B, or a plurality thereof. Eachmember 12B includes in its surface texture 14B a plurality of simulated,adjacently positioned shake elements integrally formed side by side withone another, each simulated shake element having a three-dimensionalsimulated wood grain.

It should be appreciated that both siding systems 10A, 10B can be cut(e.g., with a circular saw, table saw, tile saw, and/or the like) intoindividual siding members 12A, 12B, respectively, or portions thereof.Additionally, the cementitious siding systems 10 of the presentinvention can be installed in any number of patterns, e.g., the groundlevel can include siding system 10A and the second level or eaves caninclude siding system 10B. Furthermore, any number of complex shapes canbe formed in accordance with the teachings of the present invention,including objects that have intricate curved patterns and those withhighly complex three-dimensional shapes.

With specific reference to FIGS. 3 and 6, a log-shaped cementitioussiding system 10C can simulate a wall formed of logs. Generally,log-shaped siding members 12 have an exposed exterior surface that iscylindrically curved, and a reverse surface that is substantiallyplanar. In the illustrated embodiment, cementitious siding system 10C isa single cementitious siding member 12C, or a plurality thereof. Eachmember 12C simulates a singular wooden log, a cross section of whichtaken normal to its longitudinal direction is substantiallysemi-circular (as shown in FIG. 6). Other embodiments of log-shapedsiding members 12 may simulate two or more adjacently positioned logs,each simulated log having a cylindrically curved exposed exteriorsurface, the integrally-formed “logs” of such log-shaped cementitioussiding members 12 having a common, substantially planar reverse surface.It should be appreciated that a log-shaped cementitious siding system 10formed of siding members 12 that each simulates a plurality ofadjacently positioned logs would reduce the installation timeconsiderably.

Log-shaped cementitious siding member 12C of the present invention caninclude, without limitation, a tongue portion 30 and/or a groove portion32 (formed on either the top side/bottom side and/or the left side/rightside of the log-shaped siding system 10C) to provide a relatively easyinstallation methodology (e.g., similar to that employed when installingflooring systems available at home centers). Additionally, the exposedexterior surface of the log-shaped siding system 10C is provided with asurface texture 14C molded therein, that is intended to mimic theappearance of a conventional log, including a three-dimensional woodgrain appearance.

It should also be noted that the log-shaped siding system 10C can be cut(e.g., with a circular saw, table saw, tile saw, and/or the like) intoindividual log-shaped siding members 12C or portions thereof.Additionally, the log-shaped cementitious siding system 10 of thepresent invention can be installed in any number of patterns to eithermimic the appearance of a conventional log wall and/or the like.Furthermore, any number of complex shapes can be formed in accordancewith the teachings of the present invention, including objects that haveintricate curved patterns and those with highly complexthree-dimensional shapes. After installation of a log-shapedcementitious siding system 10, a caulking material can be applied overthe seams of the adjacent log-shaped cementitious siding members 12 tomimic a “chinking” effect found on conventional log cabins.

With specific reference to FIGS. 7 and 8, the cementitious roof shinglesystem 10D of the present invention can simulate traditional roofingshingles or tiles. Generally, the cementitious roof shingle members 12are flat or planar, and may also be elongate. In the illustratedembodiment, cementitious roof shingle system 10D is a singlecementitious roof shingle member 12D, or a plurality thereof. Eachmember 12D simulates a plurality of adjacently positioned tiles, and across section taken normal to its longitudinal direction issubstantially rectangular, but may have beveled lower edges (as shown inFIG. 8). Each tile element represented in roof shingle member 12D issimulated by a tabbed portion 40. The adjacent tabbed portions 40 formedside by side with one another in member 12D are each defined in part bya notched portion 42 to mimic the appearance of conventional asphaltshingles and/or slate tiles. Each tabbed portion 40 in roof shinglemember 12D may be further defined by including deeply formed lines,divisions, slots, and/or gaps 44 therebetween, which better mimic thelook of a conventional slate tile. If desired, a surface texture may beoptionally molded into the exposed exterior surfaces of member 12D toprovide further distinction to the cementitious roof shingle system 10D.

It should be appreciated that the cementitious roof shingle system 10Dcan be cut (e.g., with a circular saw, table saw, tile saw, and/or thelike) into individual roof shingle members 12D or portions thereof.Additionally, the cementitious roof shingle system 10 of the presentinvention can be installed in any number of patterns to either mimic theappearance of a conventional asphalt tile roof, a conventional slatetile roof, and/or the like. Furthermore, any number of complex shapescan be formed in accordance with the teachings of the present invention,including objects that have intricate curved patterns and those withhighly complex three-dimensional shapes.

The cementitious siding systems and roof shingle systems 10 of thepresent invention preferably include a mat or fabric of reinforcementmaterial 50, such as but not limited to fibers, scrims, netting, meshes,and/or the like, that can be added during formation or manufacture ofthe siding systems or roof shingle systems 10. By way of a non-limitingexample, the cementitious slurry can be permitted to infiltrate throughthe various crevices, apertures, or spaces, if present, formed in thereinforcement material 50 such that the reinforcement material 50 iscompletely surrounded and enveloped by the cementitious slurry. Thereinforcement material 50 can aid in imparting increased strength,fracture resistance, and/or flexibility to the siding systems and roofshingle systems 10.

The siding systems and roof shingle systems 10 can also optionallyinclude a foam insert or core 100 that is completely or at leastpartially or substantially completely enveloped or surrounded by thecementitious slurry. The foam core 100 can aid in the reduction of theoverall weight of the cementitious siding systems and roof shinglesystems 10, as well as providing increased flexibility thereto.

In accordance with one aspect of the present invention, the cementitiousshell 102 of a siding system or roof shingle system 10 is formed from acementitious or cement slurry. The cementitious shell 102 of sidingmember 12A, 12B and 12C and roof shingle member 12D is respectivelyindicated in FIGS. 4, 5, 6, and 8. The slurry can include hydrauliccement including, but not limited to, Portland, sorrel, slag, fly ash,or calcium alumina cement. Additionally, the cement can include acalcium sulfate alpha hemihydrate or calcium sulfate beta hemihydrate.The slurry can also utilize natural, synthetic, or chemically modifiedbeta gypsum or alpha gypsum cement. The cementitious slurry preferablyincludes gypsum cement and a sufficient amount of water added thereto toproduce a slurry having the desired consistency, i.e., not too dry nornot too watery. In accordance with one aspect of the present invention,the water is present in combination with a latex material, such that thepowdered gypsum material is combined with the latex/water mixture toform the cementitious slurry.

Gypsum is a naturally occurring mineral, calcium sulfate dihydrate,CaSO₄.2H₂O (unless otherwise indicated, hereafter, “gypsum” will referto the dihydrate form of calcium sulfate). After being mined, the rawgypsum is thermally processed to form a settable calcium sulfate, whichcan be anhydrous, but more typically is the hemihydrate, CaSO₄.½H₂O,e.g., calcined gypsum. For the familiar end uses, the settable calciumsulfate reacts with water to solidify by forming the dihydrate (gypsum).The hemihydrate has two recognized morphologies, alpha and betahemihydrate. These are selected for various applications based on theirphysical properties. Upon hydration, alpha hemihydrate is characterizedby giving rise to rectangular-sided crystals of gypsum, while betahemihydrate is characterized by hydrating to produce needle-shapedcrystals of gypsum, typically with large aspect ratio. In the presentinvention, either or both of the alpha or beta forms can be used,depending on the mechanical performance required. The beta formgenerates less dense microstructures and is preferred for low densityproducts. Alpha hemihydrate could be substituted for beta hemihydrate toincrease strength and density or they could be combined to adjust theproperties.

The cementitious slurry can also include other additives. The additivescan include, without limitation, accelerators and set preventers orretarders to control the setting times of the slurry. For example,appropriate amounts of set preventers or retarders can be added to themixture to increase the shelf life of the resulting slurry so that itdoes not cure prematurely. When the slurry to be used in moldingoperations, a suitable amount of an accelerator can be added to theslurry, either before or after the pouring operation, so as to increasethe drying and/or curing rate of the slurry. Suitable acceleratorsinclude aluminum sulfate, potassium sulfate, and Terra Alba groundgypsum. Additional additives can be used to produce colored sidingsystems and roof shingle systems 10, such as dry powder metallic oxidessuch as iron and chrome oxide and pre-dispersed pigments used forcoloring latex paints.

In accordance with one aspect of the present invention, a reinforcingmaterial can also be disposed within the cementitious slurry, eitherprior to or after the introduction of the water thereto. The reinforcingmaterial can include, without limitation, fibers, e.g., either choppedor continuous fibers, comprising at least one of polypropylene fibers,polyester fibers, glass fibers, and/or aromatic polyamide fibers. By wayof a non-limiting example, the reinforcing material can include acombination of the fibers, such as the polypropylene fibers and theglass fibers or the polyester fibers and the glass fibers or a blend ofthe polypropylene fibers and the polyester fibers and the glass fibers.If included in the fiber composition, the aromatic polyamide fibers areformed from poly-paraphenylene terephthalamide, which is a nylon-likepolymer commercially available as KEVLAR® from DuPont of Wilmington,Del. Of course, aromatic polyamide fibers other than KEVLAR® aresuitable for use in the fiber composition of the present invention.

The cementitious slurry can then be mixed, either manually orautomatically, so as to adequately combine the various ingredientsthereof and optionally can also be agitated, e.g., by a vibrating table,to remove or lessen any air bubbles that formed in the cementitiousslurry.

In accordance with one aspect of the present invention, the cementitiousslurry includes a gypsum cement material, such as but not limited tocalcined gypsum (e.g., calcium sulfate hemihydrate), also commonlyreferred to as plaster of Paris. One source of a suitable gypsum cementmaterial is readily commercially available from United States GypsumCompany (Chicago, Ill.) and is sold under the brand name HYDROCAL® FGR95. According to the manufacturer, HYDROCAL® FGR 95 includes more than95 wt. % plaster of Paris and less than 5 wt. % crystalline silica.

The gypsum cement material should include an approximate 30% consistencyrate. That is, for a 10 lb. amount of gypsum cement material,approximately 3 lbs. of water of would be needed to properly activatethe gypsum cement material. If a latex/water mixture is being used tocreate the cementitious slurry, and the mixture contains approximately50 wt. % latex solids, then approximately 6 lbs. of the latex/watermixture would be needed, as the latex/water mixture only containsapproximately 50 wt. % water, the remainder being the latex solidsthemselves.

In accordance with another aspect of the present invention, thecementitious slurry includes a melamine resin, e.g., in the dry form,which acts as a moisture resistance agent. The melamine resin is presentin an amount of about 10% of the weight of the gypsum cement material.For example, if 10 lbs. of gypsum cement material are used, thenapproximately 1 lb. of the melamine resin would be used. One source of asuitable melamine resin is readily commercially available from BallConsulting Ltd. (Ambridge, Pa.).

In accordance with still another aspect of the present invention, thecementitious slurry includes a pH adjuster, such as but not limited toammonium chloride, a crystalline salt, which acts to ensure propercross-linking of the latex/water mixture with the dry ingredients,especially the melamine resin. The ammonium chloride is present in anamount of about 1% of the weight of the gypsum cement material. Forexample, if 10 lbs. of gypsum cement material are used, thenapproximately 0.1 lbs. of the ammonium chloride would be used. Onesource of a suitable ammonium chloride is readily commercially availablefrom Ball Consulting Ltd. (Ambridge, Pa.).

In accordance with yet another aspect of the present invention, thecementitious slurry includes a filler such as but not limited to fly ash(e.g., cenosphere fly ash), which acts to reduce the overall weightand/or density of the slurry. The fly ash is present in an amount ofabout 30% of the weight of the gypsum cement material. For example, if10 lbs. of gypsum cement material are used, then approximately 3 lbs. ofthe fly ash would be used. One source of a suitable fly ash is readilycommercially available from Trelleborg Fillite Ltd. (Runcorn, England).

Several of the wet and/or dry components of the cementitious slurry ofthe present invention are readily commercially available in kit formfrom the United States Gypsum Company under the brand name REDI-ROCK®.Additional information regarding several suitable components of thecementitious slurry of the present invention can be found in U.S. Pat.No. 6,805,741, the entire specification of which is expresslyincorporated herein by reference.

One or more of the dry ingredients are to be combined with the liquidportion of the cementitious slurry, i.e., the latex/water mixture. Ifthe latex/water mixture includes 50 wt. % latex solids, with the restbeing water, then the latex/water mixture is present in an amount ofabout 60% of the weight of the gypsum cement material. For example, if10 lbs. of gypsum cement material are used, then approximately 6 lbs. ofthe latex/water mixture would be used. One source of a suitablelatex/water mixture is readily commercially available from BallConsulting Ltd. (Ambridge, Pa.) under the brand name FORTON® VF-812.According to the manufacturer, FORTON® VF-812 is a specially formulated,all acrylic co-polymer (50% solids) which cross-links with a dry resinto make the system moisture resistant and UV stable.

The resulting cementitious slurry of the present invention shouldpossess the following attributes: (1) it should stay wet or flowable foras long as possible, e.g., days, weeks, months, as circumstanceswarrant; (2) it should self level, i.e., the slurry should level byitself without intervention from the user when introduced into or onto amold face surface; and (3) it should contain a limited water content(e.g., compared to conventional gypsum cement slurries), i.e., it shouldnot be so wet so as to take a very long time (e.g., several hours oreven days) to dry or cure.

Referring to FIGS. 9-29, according to one illustrative system and methodaccording to the present invention, the above-described cementitioussiding systems 10A, 10B, and 10C, and cementitious roof shingle system10D may be formed in a substantially open mold system 200 having a loweror bottom mold retainer support 202 in which a mold surface member 204is removeably disposed. Each cementitious siding or roof shingle system10A, 10B, 10C, and 10D is respectively defined primarily by thecomparatively unique features of mold surface members 204A, 204B, 204C,and 204D, respectively shown in FIGS. 9-12, each having a different moldface 205A, 205B, 205C, and 205D that characterizes the different systems10A, 10B, 10C, and 10D.

The face 205A, 205B, 205C, 205D of the respective mold surface member204A, 204B, 204C, 204D is essentially a negative image of the desiredexposed exterior surface texture 14 and the shape of a particular typeor design of a cementitious siding system or roof shingle system 10.Additionally, the mold surface member 204 preferably includes aperipheral lip member 208 to aid in grasping the mold surface member204, e.g., when it is desired to remove the mold surface member 204 fromthe cavity 206 of lower mold retainer support 202.

Notably, the molding system 200 for forming a particular one ofcementitious siding or roof shingle systems 10A, 10B, 10C, 10D mayinclude a plurality of generally similar but slightly dissimilar moldsurface members 204 that differ from each other primarily in theirspecific surface texture-imparting features, so that all cementitioussiding or roof shingle members 12 comprising a particular system 10A,10B, 10C, 10D are not identical. For instance, there may be severalindividual and unique mold surface members 204A in the molding systemfor forming cementitious siding systems 10A, each having a slightlydifferent wood grain design in its mold face 205A.

It should be understood that the methodologies disclosed herein forboard-type cementitious siding system 10A are equally applicable to theproduction of board-type cementitious siding system 10B (provided thatmold surface member 204B having face 205B is employed). Therefore, inthe following discussion and Figures mentioned therein, board-typecementitious siding systems 10A, 10B and members 12A, 12B, and moldingprocesses therefor, are both represented with reference only to system10A and member 12A, and its associated mold surface member 204A.

Referring specifically to FIGS. 13-15, a mold surface member 204A, 204Cor 204D (referenced generally as 204) is preferably disposed within acavity 206 formed in the lower or bottom mold retainer support 202.Although the lower or bottom mold retainer support 202 is shown as beingan open shell having a substantially rectangular configuration, thelower or bottom mold retainer support 202 can have any number of variousconfigurations. The mold surface member 204 can be formed of any type ofmaterial, such as rigid or flexible materials; however, preferably themold surface member 204 is formed from a suitably flexible materialthat, e.g., can be removed from the cavity 206 (e.g., rubber, silicone,urethane and/or the like) and easily release the cured cementitiousslurry.

Referring specifically to FIGS. 16-19, because of the weights involvedof the various components, as well as the cementitious slurry, atransport device, such as a conveyor system 350, either manually orautomatically operated, can be employed to guide the mold system 200along during the manufacturing process, e.g., from an initial processingstation, to a curing station, and finally to a product removal station.In this manner, many cementitious siding or roof shingle systems 10 canbe produced sequentially and rapidly (e.g., in an assembly line process)without having to wait for each individual siding or roof shingle systemto be finally and completely manufactured.

As previously noted, in order to provide cementitious siding systems orroof shingle systems 10 of various colors to satisfy consumer demand,the cementitious slurry can contain colorants dispersed therethrough, oralternatively, the face 205 of the mold surface member 204 can be coatedwith a colorant, or in the case of a “natural cedar shake” effect, aseries of colorants can be provided to produce a multi-colored and/orvariegated siding system or roof shingle system 10. Furthermore, itshould be noted that paints, stains, sealants, and/or the like can alsobe applied to the face 205 of the mold surface member 204 before theintroduction of the cementitious slurry, or alternatively, they can beapplied to the finished product 10 after removal from the mold surfacemember 204. This process can be done in a factory setting or at aworksite, by either the installer or the homeowner.

Referring specifically to FIGS. 20-22, a mat or fabric of reinforcementmaterial 50 can be placed in the mold surface member 204, e.g., inproximity to the face 205 of the mold surface member 204. Because it isdesired that the cementitious slurry be allowed to infiltrate throughthe reinforcement material 50, it is desirable to leave a space betweenthe reinforcement material 50 and the face 205 of the mold surfacemember 204 such that the flowing cementitious slurry can fill the areatherebetween and prevent any “read through” of the reinforcementmaterial 50 on the finished surface of the siding system or roof shinglesystem 10.

Referring specifically to FIG. 23, after the cementitious slurry hasbeen prepared as described above, the cementitious slurry, preferablywhen still wet, is then sprayed or poured into the mold surface member204, either manually or mechanically, such that it contacts and fillsthe mold surface member 204 to a desired depth. By way of a non-limitingexample, the cementitious slurry is poured onto the mold surface member204 until it reaches a depth of about one-half way up the exterior wallof the mold surface member 204. Alternatively, the amount of thecementitious slurry could be added on the basis of weight, as opposed tovolume. However, it should be appreciated that either less than or morethan this amount (e.g., volume and/or weight) of the cementitious slurrycan be used, e.g., depending on the specific application.

Referring specifically to FIGS. 24 and 25, once a sufficient amount ofthe cementitious slurry is disposed onto the mold surface member 204,the optional foam core or insert 100 is then placed onto thecementitious slurry and is properly positioned in the mold in a desiredorientation. At this point, additional amounts of the cementitiousslurry is added, preferably on top of the foam core or insert 100 if afully encapsulated final product is desired, or alternatively, theadditional amount of the cementitious slurry is placed around theperiphery of the foam core or insert 100 if a partially encapsulatedfinal product is desired. An optional vibratory force can be applied tothe mold system 200, e.g., to remove any residual air bubbles in thecementitious slurry, e.g., either before or after the foam core orinsert 100 is placed therein.

The cementitious slurry is then allowed to dry, harden or cure for asufficient amount of time, which may depend, at least in part, on thespecific composition of the cementitious slurry used. The mold system200 can also be shuttled off of the conveyor system 350 and stored in astorage area (not shown) so that other siding systems or roof shinglesystems 10 can be made in the interim.

Referring specifically to FIGS. 26-29, once the cementitious slurry hasdried, hardened or cured, the siding system or roof shingle system 10can then be removed from the mold system 200. For example, the moldsurface member 204 can then be removed from the cavity 206 by grabbingthe peripheral lip member 208 and lifting the mold surface member 204upwardly and out of the cavity 206. The mold surface member 204 is thenseparated from the siding system or roof shingle system 10, thusexposing the finished product, which is preferably allowed to dry to asuitable extent, after which time it can then be used immediately orfurther processed.

Referring specifically to FIG. 30, there is shown a schematic view of afirst alternative system 300 for producing certain embodiments of thecementitious siding systems and roof shingle systems of the presentinvention, i.e., those siding systems and roof shingle systems 10 thatare generally flat or planar. Of the embodiments disclosed herein,system 300 best lends itself to the manufacture of board-typecementitious siding systems 10A and 10B, and cementitious roof shinglesystem 10D. System 300 provides a continuous method for producingrelatively long lengths of the siding systems and roof shingle systemsthat can be cut to an appropriate size, without the need to produceindividual siding systems or and roof shingle systems of limited size.The system 300 primarily includes a reinforcement material feed rollersystem 302 (including first and second material feed rollers 302 a and302 b), a cementitious slurry feed system 304, a slotted roller 306, atop roller system 308 (including first and second top rollers 308 a and308 b), and a bottom roller system 310 (including first and secondbottom rollers 310 a and 310 b).

Initially, a length of the reinforcement material 50 is fed viareinforcement material feed roller system 302 onto the surface 310 c ofbottom roller system 310. An appropriate amount of the cementitiousslurry is placed onto the reinforcement material 50 via the cementitiousslurry feed system 304. The slotted roller 306 (or other appropriateroller or other device) rotates over the cementitious slurry to forcethe cementitious slurry against reinforcement material 50, to infiltratethe slurry completely through the reinforcement material 50. As thecombined cementitious slurry/reinforcement material 50 combinationtravels through the top roller system 308 and bottom roller system 310,the cementitious slurry is contacted by a textured face 310 d formed onthe surface 310 c of the bottom roller system 310. The textured face 310d includes a pattern that is operable to impart the appropriate sidingor roof shingle surface texture or pattern to the adjacent surface ofthe cementitious slurry. The finished siding system or roof shinglesystem then passes out through the top roller system 308 and bottomroller system 310 and can be cut by an optional cutting device 312(e.g., a transverse saw) into siding systems or roof shingle systems ofappropriate length (e.g., the desired length of a particular roofshingle member design may be three “tab lengths” and/or the like),whereupon the cut siding systems or roof shingle systems can be fed ontoan optional conveyor system 314 for packaging or shipment purposes.

Referring specifically to FIG. 31, there is shown a schematic view of asecond alternative system 400 for producing other certain embodiments ofthe cementitious siding systems and roof shingle systems of the presentinvention, i.e., those siding systems and roof shingle systems 10 thatare generally flat or planar and include a foam insert or core. Of theembodiments disclosed herein, system 400 best lends itself to themanufacture of board-type cementitious siding systems 10A and 10B, andcementitious roof shingle system 10D. System 400, like system 300, alsoprovides a continuous method for producing relatively long lengths ofthe siding systems and roof shingle systems that can be cut to anappropriate size, without the need to produce individual siding systemsor roof shingle systems of limited size. The system 400 is very similarto system 300 depicted in FIG. 30, and likewise includes a reinforcementmaterial feed roller system 302 (including first and second materialfeed rollers 302 a and 302 b), a cementitious slurry feed system 304, aslotted roller 306, a top roller system 308 (including first and secondtop rollers 308 a and 308 b) and a bottom roller system 310 (includingfirst and second bottom rollers 310 a and 310 b). However, system 400differs by inclusion of a foam core feed system 402 (including first andsecond foam core feed rollers 402 a and 402 b).

As with the system 300 depicted in FIG. 30, a length of thereinforcement material 50 is fed via reinforcement material feed rollersystem 302 onto the surface 310 c of bottom roller system 310. Anappropriate amount of the cementitious slurry is placed onto thereinforcement material 50 via the cementitious slurry feed system 304.The slotted roller 306 (or other appropriate roller or other device)rotates over the cementitious slurry to force the cementitious slurryagainst reinforcement material 50, to infiltrate the slurry completelythrough the reinforcement material 50. However, in this embodiment, anappropriate or a continuous length of a foam core material 100 is fedvia foam core feed system 402 onto the “back” surface of thecementitious slurry. As the combined cementitious slurry/reinforcementmaterial 50/foam core material 100 combination travels through the toproller system 308 and bottom roller system 310, the cementitious slurryis contacted by the textured face 310 d formed on the surface 310 c ofthe bottom roller system 310. The textured face 310 d includes a patternthat is operable to impart the appropriate siding or roof shinglesurface texture or pattern to the adjacent surface of the cementitiousslurry. The finished siding system or roof shingle system then passesout through the top roller system 308 and bottom roller system 310 andcan be cut by an optional cutting device 312 (e.g., a transverse saw)into siding systems or roof shingle systems of appropriate length (e.g.,the desired length of a particular roof shingle member design may bethree “tab lengths” and/or the like), whereupon the cut siding systemsor roof shingle systems can be fed onto an optional conveyor system 314for packaging or shipment purposes.

Referring to FIGS. 32-34, an alternative system and method of formingthe log-shaped siding system 10C of the present invention is shown bywhich the log-shaped siding members 12C are formed in a substantiallyclosed mold system 500. System 500 is similar to and adapted to workwith elements of open mold system 200; however system 500 includes anupper mold member 502 that is intended to cooperate with and/or engagethe lower mold retainer support 202 and/or mold surface member 204Cdisposed therein. Upper mold member 502 may be provided within an uppermold retainer 514 which, by way of a non-limiting example, can beseparably attached to the lower mold retainer support 202 to firmlyclose mold system 500. Upper mold member 502 can be formed of any typeof material, such as rigid or flexible materials; however, preferablythe upper mold member 502 is formed from a suitably flexible materialthat, e.g., can be removed from the upper mold retainer 514 (e.g.,rubber, silicone, urethane and/or the like) and easily release the curedcementitious slurry.

Lower mold retainer support 202 may be adapted to include engagementmembers 504 that can selectively engage engagement members 506 providedon the outer surface of the upper mold retainer 514. The upper moldmember 502 can also include a opening 508 accessible through the top ofupper mold retainer 514 and suitable for permitting the introduction ofthe cementitious slurry into enclosed mold cavity 516, e.g., through anozzle 510 inserted into opening 508. Although not shown, an operatorwould hold nozzle 510 sealingly inserted into opening 508 ascementitious slurry is injected into enclosed mold cavity 516, thusproviding pressurized delivery of the slurry into closed mold system500. In this manner, the cementitious slurry can infiltrate thereinforcement material 50 and substantially fill the enclosed moldcavity 516 defined by mold surface member 204C and upper mold member502, and force any air in the enclosed mold cavity 516 out through theseam 512 formed between the upper mold member 502, the mold surfacemember 204C, the upper mold retainer 514, and the lower mold retainersupport 202.

In FIG. 33, the reinforcement material 50 is shown as being larger thanthe area of the enclosed mold cavity 516, and is maintained in placerelative to enclosed mold cavity 516 by being held within the seam 512to prevent the reinforcement material 50 from excessive sagging andbunching when the cementitious slurry is introduced into the enclosedmold cavity 516. Allowing reinforcement material 50 to overlap andextend between and beyond the superposed perimeter edges of upper moldmember 502 and mold surface member 204C, will also allow air withinenclosed mold cavity 516 to be vented therefrom by flowing through thethickness of the reinforcement material 50 as the cementitious slurry isintroduced into the enclosed mold cavity 516. Once log-shapedcementitious siding system 10C is removed from closed mold system 500,it is trimmed of flash produced in seam 512, which will typicallyinclude portions of reinforcement material 50 and cured cementitiousslurry.

FIG. 34 shows closed mold system 500 with a foam core or insert 100provided in enclosed mold cavity 516, above the reinforcement material50. As shown in FIG. 34, instead of being substantially planar as shownin FIG. 24, foam insert or core 100 may have a shape that is somewhatsimilar to that of the resulting log-shaped cementitious siding member12C. With reference to FIG. 6, core 100 could be substantiallysemi-cylindrical. Regardless of its shape, foam insert or core 100 usedin closed mold system 500 preferably has an aperture 518 formed thereinthat is aligned with opening 508 and provides a passage through whichslurry introduced into enclosed mold cavity 516 flows through the foamcore 100, to and through the reinforcement material 50, and to the face205C of mold surface member 204C. Slurry that has flowed downwardlythrough the passage formed by aperture 518 and to generally cylindricalface 205C then flows horizontally therealong and upwardly along itscurved, textured profile and its opposite axial ends, toward upper moldmember 502 and optionally into a space 520 located vertically betweenthe uppermost surface of foam insert 100 and the superposed,downwardly-facing surface of upper mold member 502. Thus the foam insert100 is at least partially, and optionally is fully, enveloped by theslurry and the resulting cementitious shell 102 of the log-shapedcementitious siding member 12C formed using closed molding system 500.

Closed mold system 500 may similarly be used to form the above-describedboard-type cementitious siding members 12A, 12B, or cementitious roofshingle member 12D, with or without a foam core 100, and is expected tomore completely and uniformly fill the cavity of mold surface member 204and impregnate reinforcement material 50 vis-à-vis the open mold system200, due to the pressurized injection of cementitious slurry intoenclosed mold cavity 516.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and may herein be described in detail. It shouldbe understood, however, that the drawings and detailed descriptiontherefore are not intended to limit the invention to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents and alternatives falling within the spiritand scope of the present invention as defined by the appended claims.

1. A siding system or roof shingle system configured to simulate, andintended to be a substitute for, traditional siding or roof shingles,respectively, said system comprising: at least one member of a pluralityof members adapted for being mounted to a dwelling, said membercomprising: a cementitious material defining a first surface exposedrelative to a dwelling to which said plurality of members is adapted forbeing mounted, said first surface configured to simulate the appearanceof at least one singular traditional siding element or roof shingleelement; a reinforcement material encapsulated by said cementitiousmaterial and proximately disposed beneath said first surface, saidreinforcement material extending substantially over the area of saidfirst surface; and a second surface opposed to said first surface, saidsecond surface defining a reverse surface that faces the dwellingsurface to which said plurality of members is adapted for being mounted;wherein said member first surface is configured to simulate theappearance of at least one singular traditional siding or roof shingleelement.
 2. A siding system or roof shingle system according to claim 1,wherein said first surface is configured to simulate the appearance of asingular traditional siding or roof shingle element selected from thegroup consisting of: a wooden board, a wooden shake, a wooden shingle, alog, a slate roof tile, and an asphalt roof shingle.
 3. A siding systemor roof shingle system according to claim 1, wherein each of saidplurality of members is generally flat.
 4. A siding system or roofshingle system according to claim 3, wherein each of said plurality ofmembers is elongate.
 5. A siding system or roof shingle system accordingto claim 4, wherein each of said plurality of members simulates theappearance of wooden board siding.
 6. A siding system or roof shinglesystem according to claim 4, wherein each of said plurality of memberssimulates the appearance of a plurality of adjacently positioned woodenshakes.
 7. A siding system or roof shingle system according to claim 1,wherein each of said plurality of members has a said first surface thatis cylindrically curved and a said second surface that is substantiallyplanar.
 8. A siding system or roof shingle system according to claim 1,wherein said member first surface has a three-dimensional pattern moldedthereinto.
 9. A siding system or roof shingle system according to claim1, wherein said member further comprises an optional foam core at leastpartially enveloped by said cementitious shell and disposed on the sideof reinforcement material opposite said first surface.
 10. A sidingsystem or roof shingle system according to claim 9, wherein saidoptional foam core defines at least a portion of said second surface.11. A siding system or roof shingle system according to claim 9, whereinsaid second surface is completely defined by said cementitious shell.12. A siding system or roof shingle system according to claim 9, whereinsaid optional foam core has a shape that is one of substantially planarand substantially semi-cylindrical.
 13. A siding system or roof shinglesystem according to claim 9, wherein said optional foam core has anaperture extending therethrough and defining a passage in whichcementitious material is disposed.
 14. A siding system or roof shinglesystem according to claim 1, wherein said member first surface isexteriorly exposed relative to a dwelling to which said plurality ofmembers is adapted for being mounted.
 15. A siding system or roofshingle system according to claim 1, wherein said system comprises asingle said member.
 16. A siding system or roof shingle system accordingto claim 1, wherein said cementitious material comprises a mixture ofgypsum cement and latex.